Method of manufacturing a tampon

ABSTRACT

In the manufacture of a tampon, an absorbent structure composed of an absorbent material can be formed into a tampon blank. In various embodiments, a withdrawal element can be attached to the absorbent structure either before or after the absorbent structure is formed into a tampon blank. The tampon blank can then undergo a compression step which can result in the pledget of the tampon. The pledget, and resultant tampon, can have at least one linear channel and at least one non-linear channel.

RELATED APPLICATION

The present application claims priority to U.S. Provisional ApplicationNo. 62/368,494, fled Jul. 29, 2016, the contents of which are herebyincorporated by reference in a manner consistent with the presentapplication.

BACKGROUND OF THE DISCLOSURE

A wide variety of products can undergo a compression step during amanufacturing process of the product. Compression of the product canalter the dimensions of the product from its original startingdimensions and reduce those dimensions to render a product with finalsmaller dimensions. An example of a personal care product which canundergo a compression step in a manufacturing process is a tampon.

Tampons generally undergo a compression step during the manufacturingprocess in order to render a tampon having a size and dimension moresuitable for insertion into the body of the user. The compression of atampon blank can result in a tampon capable of being inserted digitallyby the user's fingers or through the use of an applicator. A tampon isgenerally manufactured by folding, rolling, or stacking an absorbentstructure made of loosely associated absorbent material into a tamponblank. The tampon blank can then be compressed into a tampon of thedesired size and shape.

In use, tampons are designed to be inserted into a woman's vagina tointercept the fluid flow of menses, blood, and other body fluids and toprevent fluid from exiting the vagina. As body fluids contact the tamponthey should be absorbed and retained by the absorbent material of thetampon. After a time period, the tampon and its retained fluid isremoved and disposed.

A drawback often encountered with tampons is the tendency towardpremature failure of the tampon. For example, in general, tampons areformed from a compression process that results in straight grooveswithin the tampon. Such straight grooves can provide a pathway for bodyfluids to propagate unimpeded from the insertion end to the withdrawalend of the tampon without being sufficiently absorbed by the tampon. Thepremature failure of the tampon can result in leakage of body fluid fromthe vagina while the tampon is in place and before the tampon iscompletely saturated with the body fluid.

There is a need to provide a tampon which can have an improved handlingof body fluid. There is a need to provide a tampon in which at least aportion of the grooves are not straight such that any potential fluidpath for body exudates is lengthened thereby providing increasedretention time for the body fluid to be absorbed by the tampon. There isa need to provide a manufacturing process which can manufacture such atampon.

SUMMARY OF THE DISCLOSURE

In various embodiments, a method for compressing a tampon blank into apledget can include the steps of: providing a compression apparatus forcompressing the tampon blank, the compression apparatus comprising acompression space and a longitudinal axis; a plurality of compressionjaws wherein each compression jaw comprises a compression segment whichhas a first sidewall and an opposing second sidewall wherein the firstsidewall and the second sidewall join together to form a longitudinaldirection compression surface wherein at least one of the first sidewalland the second sidewall is oblique to a radial plane directed outwardfrom the longitudinal axis; a plurality of penetration jaws wherein eachpenetration jaw comprises a base surface comprising a longitudinaldirection and at least two penetrating segments extending from the basesurface wherein a first of the at least two penetrating segments isspaced apart from a second of the at least two penetrating segments andwherein each of the penetrating segments comprises a first sidewall andan opposing second sidewall wherein the first sidewall and the secondsidewall join together to form a compression surface; inserting thetampon blank into the compression space of the compression apparatuswherein the tampon blank comprises a longitudinal direction, alongitudinal axis, a circumferential direction, and a radial depthdirection; moving the compression jaws in a direction towards thelongitudinal axis of the compression apparatus wherein the compressionjaws move from an open position to a closed position to form a pledget;moving the penetration jaws in a direction towards the longitudinal axisof the compression apparatus wherein the penetration jaws move from anopen position to a closed position to form a non-linear channel in thepledget; retracting the penetration jaws from the pledget in a directionaway from the longitudinal axis of the compression apparatus wherein thepenetration jaws move from the closed position to the open position;ejecting the pledget from the compression apparatus; and retracting thecompression jaws in a direction away from the longitudinal axis of thecompression space wherein the compression jaws move from the closedposition to the open position.

In various embodiments, the compression apparatus comprises from 2 to 10compression jaws. In various embodiments, the compression apparatuscomprises from 2 to 10 penetration jaws.

In various embodiments, the movement of the compression jaws and thepenetration jaws is in an arcuate path in a radial direction toward thelongitudinal axis of the compression space.

In various embodiments, the movement of the compression jaws and thepenetration jaws is in a linear path in a radial direction toward thelongitudinal axis of the compression space.

In various embodiments, each penetration jaw comprises from 2 to 35penetration segments extending from the base surface. In variousembodiments, the penetration segments have a variable width between thetwo opposing sidewalls.

In various embodiments, the compression jaws are heated. In variousembodiments, the penetration jaws are heated.

In various embodiments, the penetration jaws operate independently fromthe compression jaws. In various embodiments, each penetration jawoperates synchronously with each other penetration jaw. In variousembodiments, each compression jaw operates synchronously with each othercompression jaw

In various embodiments, a longitudinal axis of the pledget isconcentrically aligned with the longitudinal axis of the compressionapparatus when the pledget is ejected from the compression apparatus.

In various embodiments, the penetration jaws are disengaged from thepledget during ejection of the pledget.

In various embodiments, the compression jaw forms a linear channel inthe tampon blank.

In various embodiments, the penetration jaws are in an open positionduring insertion of the tampon blank into the compression apparatus.

In various embodiments, the longitudinal axis of the tampon blank isconcentrically aligned with the longitudinal axis of the compressionapparatus during insertion of the tampon blank into the compressionapparatus.

In various embodiments, each penetration jaw forms a single non-linearchannel in the pledget. In various embodiments, each penetration jawforms a plurality of non-linear channels in the pledget.

In various embodiments, ejecting the pledget from the compressionapparatus occurs while the plurality of compression jaws are in theclosed position.

In various embodiments, the compression jaws and the penetration jawsoperate with at least a portion of the relative motion beingasynchronous with each other.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1A-1C are side views of exemplary embodiments of tampons.

FIG. 2A is a perspective view of an exemplary embodiment of an absorbentstructure.

FIG. 2B is a top down view of an exemplary embodiment of an absorbentstructure.

FIGS. 3A and 3B are perspective views of exemplary embodiments of tamponblanks.

FIG. 4 is a close-up view of a portion of the tampon of FIG. 1.

FIGS. 5A-5L are lateral cross-sections of illustrative exemplaryembodiments of the shape of an inner surface of a linear channel.

FIG. 6 is a longitudinal cross-section of an illustration of anexemplary embodiment of a non-linear channel.

FIG. 7 is a schematic illustration of an exemplary embodiment of amethod for compressing a tampon blank.

FIG. 8 is a perspective view of an illustration of an exemplaryembodiment of a compression jaw.

FIGS. 8A-8L are lateral cross-sectional end view illustrations ofexemplary embodiments of compression segments.

FIG. 9A is a perspective view of an exemplary embodiment of apenetration jaw.

FIG. 9B is a bottom view of the penetration jaw of FIG. 9A.

FIG. 9C a side view of the penetration jaw of FIG. 9A.

FIG. 9D is a close-up view of a portion of the penetration jaw of FIG.9C.

FIG. 10 is a side view of an exemplary embodiment of a penetration jaw.

FIG. 10A is a bottom view of the penetration jaw of FIG. 10.

FIG. 11 is a side view of an exemplary embodiment of a penetration jaw.

FIG. 11A is a perspective view of the penetration jaw of FIG. 11.

FIG. 12 is a side perspective view of an exemplary embodiment of apenetration jaw.

FIG. 13 is a side view of an exemplary embodiment of a tampon.

FIG. 14 is a schematic illustration of a compression apparatus whereinthe compression jaws and the penetration jaws move in an arcuate pathtowards the longitudinal axis of the compression space of thecompression apparatus and wherein the compression jaws and thepenetration jaws are in an open configuration to receive an uncompressedtampon blank.

FIG. 15 is a schematic illustration of the compression apparatus of FIG.14 with the compression jaws in a closed configuration and compressing atampon blank to form a tampon pledget.

FIG. 16 is a schematic illustration of the compression apparatus of FIG.14 with the compression jaws and penetration jaws in a closedconfiguration and compressing the tampon pledget.

FIG. 17 is a schematic illustration of the compression apparatus of FIG.14 with the penetration jaws in an open configuration and completelywithdrawn from the tampon pledget and the compression jaws in a closedconfiguration.

FIG. 18 is a schematic illustration of a compression apparatus whereinthe compression jaws and penetration jaws move in a linear path towardsthe longitudinal axis of the compression space of the compressionapparatus and wherein the compression jaws and the penetration jaws arein an open configuration.

Repeat use of reference characters in the present specification anddrawings is intended to represent the same or analogous features orelements of the disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure is directed towards a tampon designed to beinserted above the introital region of a woman's vaginal cavity. Thetampon is designed to function so as to intercept body fluids such asmenses, blood, and other body fluids and prevent the body fluids fromexiting the vaginal cavity. In the manufacture of a tampon, an absorbentstructure composed of an absorbent material can be formed into a tamponblank. In various embodiments, a withdrawal element can be attached tothe absorbent structure either before or after the absorbent structureis formed into a tampon blank. The tampon blank can then undergo acompression step which can result in the pledget of the tampon. Thepledget, and resultant tampon, can have at least one linear channel andat least one non-linear channel.

Definitions

The term “applicator” refers herein to a device that facilitates theinsertion of a tampon Into the vaginal cavity of a female. Non-limitingexamples of such include any known hygienically designed applicator thatis capable of receiving a tampon, including the so-called telescoping,barrel and plunger, and compact applicators.

The term “attached” refers herein to configurations in which a firstelement is secured to a second element by joining the first element tothe second element. Joining the first element to the second element canoccur by joining the first element directly to the second element,indirectly such as by joining the first element to an intermediatemember(s) which in turn can be joined to the second element, and inconfigurations in which the first element is integral with the secondelement (i.e., the first element is essentially part of the secondelement). Attachment can occur by any method deemed suitable including,but not limited to, adhesives, ultrasonic bonds, thermal bonds, pressurebonds, mechanical entanglement, hydroentanglement, microwave bonds,sewing, or any other conventional technique. The attachment can extendcontinuously along the length of attachment, or it may be applied in anintermittent fashion at discrete intervals.

The term “bicomponent fiber” refers herein to fibers that have beenformed from at least two different polymers extruded from separateextruders but spun together to form one fiber. Bicomponent fibers arealso sometimes referred to as conjugate fibers or multicomponent fibers.The polymers can be arranged in substantially constantly positioneddistinct zones across the cross-section of the bicomponent fiber and canextend continuously along the length of the bicomponent fiber. Theconfiguration of such a bicomponent fiber may be, for example, asheath/core arrangement wherein one polymer is surrounded by another ormay be a side-by-side arrangement, a pie arrangement, or an“islands-in-the-sea” arrangement.

The term “blank” refers herein to a construction of an absorbentstructure prior to compression and/or shaping of the absorbent structureinto pledget. The absorbent structure may be rolled, folded, orotherwise manipulated into a blank prior to compression of the blankinto a pledget.

The term “compression” refers herein to the process of pressing,squeezing, compacting, or otherwise manipulating the size, shape, and/orvolume of a material to obtain an insertable tampon. For example, atampon blank can undergo compression to obtain a tampon having avaginally insertable shape. The term “compressed” refers herein to thestate of the material(s) subsequent to compression. Conversely, the term“uncompressed” refers herein to the state of the material(s) prior tocompression. The term “compressible” is the ability of the material toundergo compression.

The term “cross-section” refers herein to either a plane that isorthogonal to a longitudinal axis (a “lateral cross-section”) such asbeing orthogonal to the longitudinal axis of a tampon or beingorthogonal to the longitudinal axis of the compression apparatus; or theterm “cross-section” can also refer herein to a plane that is parallelwith the longitudinal axis (“a longitudinal cross-section”) such asbeing parallel to the longitudinal axis of the tampon or as beingparallel to the longitudinal axis of the compression apparatus.

The term “digital tampon” refers herein to a tampon which is intended tobe inserted into the vaginal cavity with the user's fingers and withoutthe aid of an applicator. Thus, digital tampons are typically visible tothe user prior to use rather than being housed in an applicator.

The term “folded” refers herein to the configuration of a blank that canbe incidental to the lateral compaction of the absorbent structure ofthe blank or may purposefully occur prior to the compression step. Sucha configuration can be readily recognizable, for example, when theabsorbent material of the absorbent structure abruptly changes directionsuch that one part of the absorbent structure bends or lies over anotherpart of the absorbent structure.

The term “generally cylindrical” refers herein to the usual shape oftampons as is well known in the art, but which also includes oblate orpartially flattened cylinders, curved cylinders, and shapes which havevarying cross-sectional areas (e.g., bottle shaped) along thelongitudinal axis.

The term “longitudinal axis” refers herein to the axis running in thedirection of the longest linear dimension of the tampon. For example,the longitudinal axis of a tampon is the axis which runs from theinsertion end to the withdrawal end.

The term “outer surface” refers herein to the visible surface of the(compressed and/or shaped) tampon prior to use and/or expansion. Atleast part of the outer surface may be smooth or alternatively may havetopographical features such as ribs, channels, a mesh pattern, or othertopographical features.

The term “pledgel” refers herein to a construction of an absorbentstructure following compression of a blank.

The term “radial axis” refers herein to the axis that runs at rightangles to the longitudinal axis of the tampon.

The term “rolled” refers herein to a configuration of the blank afterwinding the absorbent structure upon itself.

The term “tampon” refers herein to an absorbent structure that isinserted into the vaginal cavity for the absorption of body fluidtherefrom or for the acute delivery of active materials, such asmedicaments. A tampon blank may have been compressed to form a generallycylindrical tampon. While the tampon can be in a generally cylindricalconfiguration, other shapes are possible. These shapes can include, butare not limited to, having a lateral cross-section that can be describedas rectangular, triangular, trapezoidal, semi-circular, hourglass,serpentine, or other suitable shapes. Tampons have an insertion end, awithdrawal end, a withdrawal element, a length, a width, a longitudinalaxis, a radial axis, and an outer surface. The tampon's length can bemeasured from the insertion end to the withdrawal end along thelongitudinal axis. A typical tampon can have a length from about 30 mmto about 60 mm. A tampon can be linear or non-linear in shape, such as,for example, curved along the longitudinal axis. A typical tampon canhave a width from about 2 mm to about 30 mm. The width of the tampon,unless otherwise stated, corresponds to the measurement across thelargest transverse cross-section along the length of the tampon.

The term “vaginal cavity” refers herein to the internal genitalia of themammalian female in the pudendal region of the body. The term generallyrefers to the space located between the introitus of the vagina(sometimes referred to as the sphincter of the vagina or the hymenealring) and the cervix. The term does not include the interlabial space,the floor of the vestibule, or the externally visible genitalia.

Tampon:

The present disclosure is directed towards a tampon designed to beinserted above the introital region of a woman's vaginal cavity. Thetampon is designed to function so as to intercept body fluids such asmenses, blood, and other body fluids and prevent the body fluids fromexiting the vaginal cavity. In the manufacture of a tampon, an absorbentstructure composed of an absorbent material can be formed into a tamponblank. In various embodiments, a withdrawal element can be attached tothe absorbent structure either before or after the absorbent structureis formed into a tampon blank. The tampon blank can then undergo acompression step which can result in the pledget of the tampon. Thepledget, and resultant tampon, can have at least one linear channel andat least one non-linear channel.

FIGS. 1A, 1B, and 1C illustrate side views of exemplary tampons 10. Thetampon 10 can have a compressed, generally cylindrical shaped absorbentpledget 12 composed of an absorbent material 14 and a withdrawal element16. In various embodiments, the withdrawal element 16 can have a knot 18which can ensure that the withdrawal element 16 does not separate fromthe pledget 12. The tampon 10 can have a longitudinal direction (Y), acircumferential direction (X), and a radial depth direction (Z). Invarious embodiments, the generally cylindrical shape of the pledget 12can have a lateral cross-section that is at least one of oval, circle,square, rectangle, or any other lateral cross-sectional shape known inthe art. The tampon 10 can have an insertion end 20 and a withdrawal end22. The tampon 10 can have a tampon length 24 wherein the tampon length24 is the measurement of the tampon 10 along the longitudinal axis 26originating at one end (insertion or withdrawal) of the tampon 10 andending at the opposite end (insertion or withdrawal) of the tampon 10.In various embodiments, the tampon 10 can have a tampon length 24 fromabout 30 mm to about 60 mm. In various embodiments, the tampon 10 canhave a compressed width 28, which unless otherwise stated herein, cancorrespond to the greatest lateral cross-sectional dimension along thelongitudinal axis 26 of the tampon 10. In various embodiments, thetampon 10 can have a compressed width 28 prior to usage from about 2, 5,or 8 mm to about 10, 12, 14, 16, 20 or 30 mm. In various embodiments,the tampon 10 may be straight or non-linear in shape, such as curvedalong the longitudinal axis 26.

As noted above, the tampon 10 can have an absorbent pledget 12 which isformed via the compression of a tampon blank 30. The tampon blank 30 isformed, in turn, from an absorbent structure 32 which is composed of anabsorbent material 14. FIG. 2A illustrates a perspective view of anexemplary embodiment of an absorbent structure 32 composed of absorbentmaterial 14. The absorbent structure 32 illustrated in FIG. 2A isgenerally in the shape of a square. A withdrawal element 16 having aknot 18 is also associated with the absorbent structure 32. FIG. 2Billustrates a top down view of an exemplary embodiment of an absorbentstructure 32 composed of absorbent material 14. The absorbent structure32 illustrated in FIG. 2B has a generally chevron shape. A withdrawalelement 16 having a knot 18 is also associated with the absorbentstructure 32. It is to be understood that these two shapes, square andchevron, are illustrative and the absorbent structure 32 can have anyshape, size, and thickness that can ultimately be compressed to form atampon 10, such as, for example, tampon 10 in FIGS. 1A-1C. Non-limitingexamples of the shape of an absorbent structure 32 can include, but arenot limited to, oval, round, chevron, square, rectangular, and the like.

In an embodiment, the absorbent structure 32 can have a length dimension34 from about 30 mm to about 80 mm. The length dimension 34 can be thelinear measurement from the portion of the absorbent structure 32 whichwill ultimately form the insertion end 20 of the tampon 10 to theportion of the absorbent structure 32 which will ultimately form thewithdrawal 22 end of the tampon 10. In an embodiment, the basis weightof the absorbent structure 32 can range from about 15, 20, 25, 53, 75,90, 100, 110, 120, 135, or 150 gsm to about 1,000, 1,100, 1,200, 1,300,1,400, or 1,500 gsm.

The absorbent structure 32 can have a single layer of absorbent material14 or the absorbent structure 32 can be a laminar structure that canhave individual distinct layers of absorbent material 14. In anembodiment in which the absorbent structure 32 has a laminar structure,the layers can be formed from a single absorbent material and/or fromdifferent absorbent materials.

The absorbent material 14 of the absorbent structure 32 can be absorbentfibrous material. Such absorbent material 14 can include, but is notlimited to, natural and synthetic fibers such as, but not limited to,polyester, acetate, nylon, cellulosic fibers such as wood pulp, cotton,rayon, viscose, LYOCELL® such as from Lenzig Company of Austria, ormixtures of these or other cellulosic fibers. Natural fibers caninclude, but are not limited to, wool, cotton, flax, hemp, and woodpulp. Wood pulps can include, but are not limited to, standard softwoodfluffing grade such as CR-1654 (US Alliance Pulp Mills, Coosa, Ala.).Pulp may be modified in order to enhance the inherent characteristics ofthe fibers and their processability, such as, for example, by crimping,curling, and/or stiffening. The absorbent material 14 can include anysuitable blend of fibers. For example, the absorbent material 14 can beformed from cellulose fibers such as cotton and rayon. The absorbentfibers can be 100 wt % cotton, 100 wt % rayon, or as blend of cotton andrayon.

In various embodiments, the absorbent fibers can have a staple length offrom about 5, 10, 15 or 20 mm to about 30, 40, or 50 mm. In variousembodiments, the absorbent fibers can have a fiber size of from about 15microns to about 28 microns. In various embodiments, the absorbentfibers can have a denier of from about 1 or 2 to about 6. Denier is aunit of fineness of yarn based on a standard of 50 milligrams (mg) for450 meters of yarn. In various embodiments, the absorbent fibers canhave a circular, bi-lobal, or tri-lobal cross-sectional configuration orany other configuration known to those skilled in the art. A bi-lobalconfiguration can have a cross-sectional profile which can look like adog bone while a tri-lobal configuration can have a cross-sectionalprofile which can look like a “Y”. In various embodiments, the absorbentfibers can be bleached. In various embodiments, the absorbent fibers canhave a color.

In various embodiments, the absorbent structure 32 can contain fiberssuch as binder fibers. In an embodiment, the binder fibers can have afiber component which will bond or fuse to other fibers in the absorbentstructure 32. Binder fibers can be natural fibers or synthetic fibers.Synthetic fibers include, but are not limited to, those made frompolyolefins, polyamides, polyesters, rayon, acrylics, viscose,superabsorbents, LYOCELL® regenerated cellulose, and any other suitablesynthetic fiber known to those skilled in the art. The fibers can betreated by conventional compositions and/or processes to enable orenhance wettability.

In various embodiments, the absorbent structure 32 can have any suitablecombination and ratio of fibers. In an embodiment, the absorbentstructure 32 can include from about 70 or 80 wt % to about 90 or 95 wt %absorbent fibers and from about 5 or 10 wt % to about 20 or 30 wt %binder fibers. In various embodiments, the absorbent structure 32 caninclude about 85 wt % absorbent fibers and about 15 wt % binder fibers.In various embodiments, the absorbent structure 32 can include fromabout 80 to about 90 wt % tri-lobal viscose rayon fibers and from about10 to about 20 wt % bicomponent binder fibers. In various embodiments,the absorbent structure 32 can include 85 wt % tri-lobal viscose rayonfibers and about 15 wt % bicomponent binder fibers. In variousembodiments, the absorbent structure 32 can include greater than about70, 80, 90, 95, 97 or 99 wt % absorbent fibers.

Various methods known to those skilled in the art can be used to preparethe absorbent structure 32. Such methods can include, but are notlimited to, airlaying, carding, wetlaying, needlepunching, mechanicalentanglement, hydroentangling, and any other known method deemedsuitable by one of ordinary skill. In various embodiments, a bondedcarded web can be made from staple fibers. In such embodiments, thefibers can be longer than about 20, 30, or 35 mm. The fibers can bepurchased in bales which can be placed in a picker to separate thefibers. The fibers can then be sent through a combing or carding unit,which can further break apart and align the fibers in the machinedirection to form a generally machine direction-oriented fibrousnonwoven web. Once the web is formed, it can then be bonded by one ormore of several known bonding methods, such as air bonding or patternbonding. In various embodiments, a dry laid web can be made from staplefibers. In such embodiments, the fibers can be about 20 mm or longer. Indry laying, fibers or tufts of fibers of a first type (e.g., absorbentfibers and/or binder fibers) can be fed to a first rotating vacuum drumand fibers or tufts of fibers of 2 second type (e.g., absorbent fibersand/or binder fibers) can be fed to a second rotating vacuum drum. Thefibers can then be laid down by suction to form mats of fibers. The matsof fibers can be doffed from the vacuum drums and combed via rotatinglickerins. The lickerins can have peripheral teeth which can comb thefibers from the mat. The combed fibers can be doffed from the lickerinsvia centrifugal force and placed into a fiber mixing and expansionchamber. The mixed fibers can be placed on a vacuum screen to form arandom fiber web comprising the first and second type fibers. The flowand velocity of each independent fiber stream can be controlled toprovide the desired quantity of each fiber type.

In various embodiments in which binder fibers are present, the binderfibers can be activated to create a three-dimensional fiber matrix. Insuch an embodiment, the activation can be completed by any suitableheating step including, but not limited to, conventional heating,through air heating, superheated steam, microwave heating, radiantheating, radio frequency heating, and the like, and combinationsthereof. In various embodiments, the activation can be followed by acooling step which can utilize any suitable means for reducing thetemperature of the absorbent structure 32.

In various embodiments, a cover can be provided as known to one ofordinary skill in the art. As used herein, the term “cover” relates tomaterials that are in communication with and cover or enclose surfaces,such as, for example, an outer surface 36 of the tampon 10. The covermay be beneficial in assuring that the fibers of the tampon 10 do notdirectly contact the inner walls of the woman's vaginal cavity.Additionally, the cover can reduce the ability of portions (e.g., fibersand the like) from becoming separated from the tampon 10 and being leftbehind upon removal of the tampon 10 from the woman's vaginal cavity. Invarious embodiments, the cover can be a fluid-permeable cover. By“fluid-permeable” it is meant that body fluid is able to pass throughthe cover. The cover can be hydrophobic or hydrophilic. In variousembodiments in which the cover is hydrophobic, the cover can be treatedwith a surfactant or other material to make it hydrophilic.

In various embodiments, the cover can be formed from nonwoven materialsor aperture films. The nonwoven materials can include, but are notlimited to, materials such as natural fibers, synthetic fibers, orblends of natural and synthetic fibers. Natural fibers can include, butare not limited to, rayon, cotton, wood pulp, flax, and hemp. Syntheticfibers can include, but are not limited to, fibers such as polyester,polyolefin, nylon, polypropylene, polyethylene, polyacrylic, vinylpolyacetate, polyacrylate, cellulose acetate, or bicomponent fibers,such as bicomponent polyethylene and polypropylene fibers. The cover canbe made by any number of suitable techniques such as, for example, beingspunbond, carded, hydroentangled, thermally bonded, and resin bonded. Invarious embodiments, the cover can be a 12 gsm smooth calendaredmaterial made from bicomponent, polyester sheath and polyethylene core,fibers such as Sawabond 4189 available from Sandler AG, Schwarzenbach,Germany. In various embodiments, the cover can be formed from anaperture thermoplastic film having either a two-dimensional or athree-dimensional thickness. In various embodiments, the cover can bebleached. In various embodiments, the cover can have a color.

In various embodiments, the absorbent structure 32 may be attached to awithdrawal element 16. The withdrawal element 16 may be attached to theabsorbent structure 32 in any suitable manner as known to one ofordinary skill in the art. A knot 18 can be formed near the free ends ofthe withdrawal element 16 to assure that the withdrawal element 16 doesnot separate from the absorbent structure 32. The knot 18 can also serveto prevent fraying of the withdrawal element 16 and to provide a placewhere a woman can grasp the withdrawal element 16 when she is ready toremove the tampon 10 from her vaginal cavity. The withdrawal element 16can be constructed from various types of threads or ribbons. A thread orribbon can be made from 100% cotton fibers and/or other materials inwhole or in part. The withdrawal element 16 can have any suitable lengthand/or the withdrawal element 16 can be dyed and/or treated with ananti-wicking agent, such as wax, before being attached to the absorbentstructure 32.

The absorbent structure 32 can be rolled, stacked, folded, or otherwisemanipulated into a tampon blank 30 before compressing the tampon blank30 into a pledget 12. FIG. 3A is an illustration of a perspective viewof an example of a rolled tampon blank 30, such as a radially woundtampon blank 30. FIG. 3B is an illustration of a perspective view of anexample of a folded tampon blank 30. It is to be understood thatradially wound and folded configurations are illustrative and additionaltampon blank 30 and pledget 12 configurations are possible. For example,suitable menstrual tampons may include “cup” shaped tampon blanks andpledgets like those disclosed in U.S. Publication No. 2008/0287902 toEdgett and U.S. Pat. No. 2,330,257 to Bailey; “accordion” or “W-folded”tampon blanks and pledgets like those disclosed in U.S. Pat. No.6,837,882 to Agyapong; “radially wound” tampon blanks and pledgets likethose disclosed in U.S. Pat. No. 6,310,269 to Friese; “sausage” type or“wad” tampon blanks and pledgets like those disclosed in U.S. Pat. No.2,464,310 to Harwood; “M-folded” tampon blanks and pledgets like thosedisclosed in U.S. Pat. No. 6,039,716 to Jessup; “stacked” tampon blanksand pledgets like those disclosed in U.S. 2008/0132868 to Jorgensen; or“bag” type tampon blanks and pledgets like those disclosed in U.S. Pat.No. 3,815,601 to Schaefer.

A suitable method for making “radial wound” tampon blanks and pledgetsis disclosed in U.S. Pat. No. 4,816,100 to Friese. Suitable methods formaking “W-folded” tampon blanks and pledgets are disclosed in U.S. Pat.No. 6,740,070 to Agyapong; U.S. Pat. No. 7,677,189 to Kondo; and U.S.2010/0114054 to Mueller. A suitable method for making “cup” tamponblanks and pledgets and “stacked” tampon blanks and pledgets isdisclosed in U.S. 2008/0132868 to Jorgensen.

In various embodiments, the tampon blank 30 can be compressed into apledget 12. The tampon blank 30 may be compressed any suitable amount.For example, the tampon blank 30 can be compressed at least about 25%,50%, or 75% of the initial dimensions. For example, a tampon blank 30can be reduced in diameter to approximately ¼ of the originaluncompressed diameter. The lateral cross-sectional configuration of theresultant tampon 10 may be circular, ovular, elliptical, rectangular,hexagonal, or any other suitable shape.

Referring to FIGS. 1A-10, following compression of the tampon blank 30to form the pledget 12, the pledget 12 and the resultant tampon 10 canhave at least one linear channel 40 and at least one non-linear channel50. Without being bound by theory, a tampon which does not have any typeof channel and, therefore, a tampon with a smooth outer surface, canhave difficulty in absorbing body fluid fast enough as the body fluidcan simply move over the smooth surface of the tampon and leak from thebody of the user of the tampon. Providing a tampon with a linear channel40 and a non-linear channel 50 can provide columnar strength and cancreate a void space area which is below the outer surface 36 of thetampon 10 and within which the body fluid can accumulate and be absorbedby the tampon 10 rather than simply passing over a smooth outer surfaceof a tampon and leaking from the body of the user of the tampon.

Referring to FIGS. 1A-10, and 4, a linear channel 40 is a straightchannel which can extend in the longitudinal direction (Y) of the tampon10. The linear channel 40 has a uniform dimension in the circumferentialdirection (X) at the outer surface 36 of the tampon 10 and referring toFIGS. 5A-5L a uniform lateral cross section in the radial depthdirection (Z) as the linear channel 40 extends in the longitudinaldirection (Y) of the tampon 10. In various embodiments, such as, forexample, as illustrated in FIGS. 1A-10, a linear channel 40 can extendthe total tampon length 24 from the insertion end 20 to the withdrawalend 22.

In various embodiments, a linear channel 40 can be defined by anopposing pair of outer surface edges 42 and an opposing pair of channelsidewalls 44. Each of the channel sidewalls 44 can extend from each ofthe outer surface edges 42, respectively, in a direction towards thelongitudinal axis 26 of the tampon 10. The channel sidewalls 44 canextend any depth into the tampon 10 as desired. The channel sidewalls 44can join together at an inner surface 46 of the linear channel 40wherein the inner surface 46 defines the bottom of the linear channel40. The inner surface 46 of the linear channel 40 forms a portion of theexterior of the tampon 10, however, the inner surface 46 of the linearchannel 40 is at a depth below the outer surface 36 of the tampon 10. Invarious embodiments, the depth of the linear channel 40, as measuredfrom the outer surface 35 to the inner surface 46, can be from about0.1, 0.2, 0.4, 0.6, 0.8, 1, 1.2, 1.4, 1.6, 1.8 or 2 mm to about 2.2,2.4, 2.6, 2.8 or 3 mm. The linear channel 40 can also have a widthdimension 48 as measured as the distance between the opposing pair ofouter surface edges 42. In various embodiments, the width dimension 48of the linear channel 40 can be from about 0.1, 0.2, 0.4, 0.6, 0.8, 1,1.2, or 1.4 mm to about 1.6, 1.8 or 2 mm.

The inner surface 46 of the linear channel 40 can be of any shape andconfiguration as desired. For example, referring to FIGS. 5A-5L, theinner surface 46 of the linear channel 40 can be a sharp angle betweenthe two channel sidewalls 44 such as, for example, in a V-configuration(FIGS. 5A and 5H), can be a rounded curve configuration between the twochannel sidewalls 44 such as, for example, in a rounded-V configuration(FIGS. 5B, 5G, and 5L), can have an arcuate shape and more width in thecircumferential direction (X) of the tampon than a rounded-Vconfiguration such as, for example, a U-configuration (FIGS. 5C and 5K),can have a flat inner surface 46 while at least one of the sidewalls 44remain at an angle to the longitudinal axis 26 of the tampon 10, suchas, for example, as can be seen in FIGS. 5D, 5E, 5F, 5I, and 5J. It isto be understood that these are non-limiting examples of the innersurface 46 configuration and other configurations are possible as deemedsuitable by one of ordinary skill.

Referring to FIGS. 1A-10, and 4, a non-linear channel 50 can extend inat least a portion of the longitudinal direction (Y) of the tampon 10.In various embodiments, such as illustrated in FIG. 1A, a non-linearchannel 50 can extend the total tampon length 24 from the insertion end20 to the withdrawal end 22. In various embodiments, such as illustratedin FIG. 1B, a non-linear channel 50 can extend a portion of the tamponlength 24. For example, as illustrated in FIG. 1B a non-linear channel50 can extend from the insertion end 20 to approximately the middle ofthe tampon length 24 of the tampon 10. In various embodiments in which anon-linear channel 50 extends only a portion of the tampon length 24 ofthe tampon 10, a non-linear channel 50 can extend from the insertion end20 to the middle of the tampon length 24 of the tampon 10, from thewithdrawal end 22 to the middle of the tampon length 24 of the tampon10, or can be present in the middle third of the tampon 10 withoutextending to either of the insertion end 20 or withdrawal end 22. Invarious embodiments in which a non-linear channel 50 extends only aportion of the tampon length 24 of the tampon 10, the tampon 10 can havemultiple non-linear channels 50 present in a common region of the tampon10 such as, for example, a tampon 10 can have a first non-linear channel50 in a spaced apart relationship in the longitudinal direction (Y) froma second non-linear channel 50. For example, as illustrated in FIG. 1C,a tampon 10 can have a first non-linear channel 50 present at theinsertion end 20 and extending in the longitudinal direction (Y) towardsthe middle of the tampon length 24 of the tampon 10 and a secondnon-linear channel 50 present at the withdrawal end 22 of the tampon andextending towards the middle of the tampon length 24 of the tampon 10wherein the first non-linear channel 50 and the second non-linearchannel 50 are present in the same longitudinal plane of the tampon 10and separated from each other by a distance in the longitudinaldirection (Y).

Referring to FIGS. 1A-1C, and 4, in various embodiments, a non-linearchannel 50 can be defined by an opposing pair of outer surface edges 52and an opposing pair of channel sidewalls 54. Each of the channelsidewalls 54 can extend from each of the outer surface edges 52,respectively, in a direction towards the longitudinal axis 26 of thetampon 10. In various embodiments, a non-linear channel 50 can undulatein the radial depth direction (Z) as the non-linear channel 50 extendsin at least a portion of the longitudinal direction (Y) of the tampon10. In various embodiments, a non-linear channel 50 can undulate in thecircumferential direction (X) as the non-linear channel 50 extends in atleast a portion of the longitudinal direction (Y) of the tampon 10. Invarious embodiments, a non-linear channel 50 can undulate in the radialdepth direction (7) as well as in the circumferential direction (X) asthe non-linear channel 50 extends in at least a portion of thelongitudinal direction (Y) of the tampon 10.

In various embodiments, a width between the channel surface edges 52 ofa non-linear channel 50, measured at the outer surface 36 of the tampon10, can be uniform in a least a portion of the non-linear channel 50. Invarious embodiments, a width between the channel surface edges 52 of anon-linear channel 50, measured at the outer surface 36 of the tampon10, can be uniform throughout the extent of the non-linear channel 50.In various embodiments, a width between the channel surface edges 52 ofa non-linear channel 50, measured at the outer surface 36 of the tampon10, can vary in at least a portion of the non-linear channel 50. Invarious embodiments, a width between the channel surface edges 52 of anon-linear channel 50, measured at the outer surface 36 of the tampon10, can vary throughout the extent of the non-linear channel 50.

Referring to FIG. 6, in various embodiments, a non-linear channel 50 canbe defined by an undulation in the radial depth direction (Z) as thenon-linear channel 50 extends in at least a portion of the longitudinaldirection (Y) of the tampon 10. The sidewalls 54 of the non-linearchannel 50 can join together at an inner surface wherein the innersurface defines the bottom of the non-linear channel 50. The undulationin the radial depth direction (Z) can result in a portion of the innersurface, such as first portion 64, defining a crest 80 and a portion ofthe inner surface, such as second portion 76, defining a trough 82. Invarious embodiments, a non-linear channel 50 can have at least 1, 2, 3,4, 5, 6, 7, 8, 9, or 10 crests 80 and can have at least 1, 2, 3, 4, 5,6, 7, 8, 9, or 10 troughs 82. In an embodiment, a non-linear channel 50can have at least 2 crests 80 and 1 trough 82. In an embodiment, anon-linear channel 50 can have at least 1 crest 80 and 2 troughs 82. Thenon-linear channel 50, therefore, can have a variable depth dimensionbelow the outer surface 36 of the tampon 10. The variable depthdimension below the outer surface 36 of the tampon 10 can result introughs 82 where body fluid can pool while awaiting absorption by thetampon 10 and the crests 80 can provide barrier to movement of the bodyfluid out of the troughs 82 in the longitudinal direction (Y) of thetampon 10. In various embodiments, the non-linear channel 50 can have apattern of crests 80 and troughs 82 wherein the crests 80 have a firstdepth dimension 84 below the outer surface 36 of the tampon 10 and thetroughs 82 have a second depth dimension 86 below the outer surface 36of the tampon 10. The first depth dimension 84 is different from thesecond depth dimension 86. In various embodiments, the first depthdimension 84 of a crest 80, as measured at the midpoint of the crest 80,of the non-linear channel 50 is from about 0.25, 0.3, 0.35 or 0.4 mm toabout 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, or 0.75 mm. In variousembodiments, the second depth dimension 86 of a trough 82, as measuredat the midpoint of the trough 82, of the non-linear channel 50 is fromabout 0.8, 0.85, 0.9, 0.95, or 1.0 mm to about 1.05, 1.1, 1.15, 1.2,1.25, 1.3, or 1.35 mm. The first depth dimension 84 and the second depthdimension 86 are measured at the middle of the respective crest 80 andtrough 82 and from the outer surface 36 of the tampon 10 to therespective first portion 64 of the inner surface and the second portion76 of the inner surface. In various embodiments, the troughs 82 of thenon-linear channel 50 can be separated from each other by a distance 88of less than about 8, 7.6, 7, 6.6, 6, 5.6, or 5 mm. In variousembodiments, as the non-linear channel 50 undulates in the radial depthdirection (Z), the width between the between the channel surface edges52, as measured at the outer surface 36 of the tampon 10, can beuniform. In various embodiments, as the non-linear channel 50 undulatesin the radial depth direction (Z), the width between the channel surfaceedges 52, as measured at the outer surface 36 of the tampon 10, can bevaried. In various embodiments, the width between the channel surfaceedges 52, as measured at the outer surface 36 of the tampon 10, can befrom about 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, or 0.8 mmto about 0.85, 0.9, 0.95, 1, 1.05, 1.1, 1.15, 1.2, 1.25, 1.3, 1.35, 1.4,1.5, 1.75, 2.0, 2.5, 3.0, 3.5, 4.0, 5.0, or 6.0 mm. The first portion 64of the inner surface and the second portion 76 of the inner surface canbe of any shape and configuration as desired. For example, the firstportion 64 of the inner surface and the second portion 76 of the innersurface can be any of the shapes and configuration as described for theinner surface 46 of the linear channel 40, such as described andillustrated in FIGS. 5A-5L. It is to be understood that these arenon-limiting examples of configuration of inner surfaces and otherconfiguration are possible as deemed suitable by one of ordinary skill.

In various embodiments, referring to FIGS. 1A-10, and 4, the non-linearchannel 50 can be defined by an undulation in the circumferentialdirection (X) as the non-linear channel 50 extends in at least a portionof the longitudinal direction (Y) of the tampon 10. In variousembodiments, the undulations in the circumferential direction (X) of anon-linear channel 50 can be defined by the sidewalls 54 of thenon-linear channel 50 moving back-and-forth (i.e., to theleft-and-right) in the circumferential direction (X) in a congruentmanner with each other. In other words, each of the sidewalls 54 of anon-linear channel 50 resemble each other (such as can be seen in FIGS.1A-10, and 4). In various embodiments, the undulations in thecircumferential direction (X) of a non-linear channel 50 can be definedby the sidewalls 54 of the non-linear channel 50 moving back-and-forth(i.e., to the left-and-right) in the circumferential direction (X) in anon-congruent manner with each other. In other words, each of thesidewalls 54 of a non-linear channel 50 are mirror images of each other.In various embodiments, a non-linear channel 50 can have a first portionin which the sidewalls 54 are congruent with each other and can have asecond portion in which the sidewalls 54 are not congruent with eachother (such as can be seen in FIG. 13). The undulations in thecircumferential direction (X) can provide a back-and-forth pathway forthe body fluid to follow. The change in direction of the pathway canslow the movement of the body fluid and can enable more body fluid to beabsorbed by the tampon 10. As the tampon 10 can have at least one linearchannel 40, a non-linear channel 50 which can undulate in thecircumferential direction (X) does not intersect the linear channel 40of the tampon 10.

In various embodiments, as the non-linear channel 50 undulates in thecircumferential direction (X) of the tampon 10, a width between thechannel surface edges 52, as measured at the outer surface 36 of thetampon 10, of the non-linear channel 50 can be uniform. In suchembodiments, a width between the channel surface edges 52 of thenon-linear channel 50, as measured at the outer surface 36 of the tampon10, can be from about 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 0.75,or 0.8, mm to about 0.85, 0.9, 0.95, 1, 1.05, 1.1, 1.15, 1.2, 1.25, 1.3,1.35, 1.4, 1.5, 1.75, 2.0, 2.5, 3.0, 3.5, 4.0, 5.0, or 6.0 mm. Invarious embodiments, as the non-linear channel 50 undulates in thecircumferential direction (X) of the tampon 10, a width between thechannel surface edges 52, as measured at the outer surface 36 of thetampon 10, of the non-linear channel 50 can vary as is illustrated inFIGS. 1A-10, and 4. In such embodiments in which a non-linear channel 50has a variable width, a non-linear channel 50 can have a first width 62between the channel surface edges 52, as measured at the outer surface36 of the tampon 10, from about 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65,0.7, 0.75, or 0.8, mm to about 0.85, 0.9, 0.95, 1, 1.05, 1.1, 1.15, 1.2,1.25, 1.3, 1.35, 1.4, 1.5, 1.75, 2.0, 2.5, 3.0, 3.5, 4.0, 5.0, or 6.0 mmand the non-linear channel 50 can have a second width 74 between thechannel sidewalls 54, as measured at the outer surface 36 of the tampon10, from about 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, or 0.8,mm to about 0.85, 0.9, 0.95, 1, 1.05, 1.1, 1.15, 1.2, 1.25, 1.3, 1.35,1.4, 1.5, 1.75, 2.0, 2.5, 3.0, 3.5, 4.0, 5.0, or 6.0 mm wherein thefirst width 62 and the second width 74 are not the same. The sidewalls54 of the non-linear channel 50 can join together at an inner surfacewhich Is below the outer surface 36 of the tampon 10 and forms thebottom of the non-linear channel 50. The inner surface can be of anyshape and configuration as desired. For example, the sidewalls 54 of thenon-linear channel 50 can be perpendicular to the second portion of theinner surface 76 or the sidewalls 54 of the non-linear channel 50 can beoblique to the second portion of the inner surface 76 and for examplecan be any of the shapes and configuration as described for the innersurface 46 of the linear channel 40, such as described and illustratedin FIGS. 5A-5L. It is to be understood that these are non-limitingexamples of configuration of inner surfaces and other configuration arepossible as deemed suitable by one of ordinary skill.

In various embodiments, a non-linear channel 50 can undulate in thecircumferential direction (X) as well as the radial depth direction (Z)as the non-linear channel 50 extends in at least a portion of thelongitudinal direction (Y) of the tampon 10. A non-linear channel 50having undulations in both the circumferential direction (X) and theradial depth direction (Z) can provide a benefit of not only creating apathway for the body fluid to follow, but creating a tortuous pathwayfor the body fluid to follow in the longitudinal direction (Y) of thetampon 10 as the body fluid is following a pathway in both a left andright movement and an up and down movement. Such a tortuous pathwaycreated by the non-linear channel 50, while providing a void space forthe accumulation of the body fluid, can slow the movement of the bodyfluid through the non-linear channel 50 in the longitudinal direction(Y) of the tampon 10.

In such embodiments in which the non-linear channel 50 can undulate inboth the circumferential direction (X) as well as the radial depthdirection (Z), the non-linear channel 50 can have multiple regions whichhave differing characteristics from each other. In various embodiments,a region of such a non-linear channel 50 may include a crest 80 and auniform width between channel surface edges 52, or may include a crest80 and a variable width between channel surface edges 52, or may includea trough 82 and a uniform width between channel surface edges 52, or mayinclude a trough 82 and a variable width between channel surface edges52. Such regions can be present in the non-linear channel 50 while thechannel also undulates in the circumferential direction (X) as itextends in at least a portion of the longitudinal direction (Y) of thetampon 10. For example, as illustrated in FIGS. 1A-1C, 4 and 6, as anon-linear channel 50 extends in at least a portion of the longitudinaldirection (Y) of the tampon 10, the non-linear channel 50 can undulatein the circumferential direction (X) and can have a variable depthdimension below the outer surface 36 of the tampon 10 wherein a firstportion 64 of the inner surface defines a crest 80 in the radial depthdirection (Z) and a second portion 76 of the inner surface defines atrough 82 in the radial depth direction (Z). The crest 80 can have afirst depth dimension 84 below the outer surface 36 of the tampon 10 andthe trough 82 can have a second depth dimension 86 below the outersurface 36 of the tampon 10 wherein the first depth dimension 36 and thesecond depth dimension 38 are not the same. In various embodiments, thefirst depth dimension 84 of a crest 80, as measured at the midpoint ofthe crest 80, of the non-linear channel 50 is from about 0.25, 0.3, 0.35or 0.4 mm to about 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, or 0.75 mm. Invarious embodiments, the second depth dimension 86 of a trough 82, asmeasured at the midpoint of the trough 82, of the non-linear channel 50is from about 0.8, 0.85, 0.9, 0.95, or 1.0 mm to about 1.05, 1.1, 1.15,1.2, 1.25, 1.3, or 1.35 mm. In various embodiments, the troughs 82 ofthe non-linear channel 50 can be separated from each other by a distance88 of less than about 8, 7.6, 7, 6.6, 6, 5.6, or 5 mm. As furtherillustrated in the exemplary figures, the non-linear channel 50 can havea variable width between the channel surface edges 52, as measured atthe outer surface 26 of the tampon 10, as the non-linear channelundulates in the circumferential direction (X). For example, asillustrated in the figures, the non-linear channel 50 can have a firstregion 60 wherein a first width 62 between the channel surface edges 52,as measured at the outer surface 36 of the tampon 10, is from about0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, or 0.8, mm to about0.85, 0.9, 0.95, 1, 1.05, 1.1, 1.15, 1.2, 1.25, 1.3, 1.35, 1.4, 1.5,1.75, 2.0, 2.5, 3.0, 3.5, 4.0, 5.0, or 6.0 mm and the non-linear channel50 can have a second region 70 with a second width 74 between thechannel surface edges 52, as measured at the outer surface 36 of thetampon 10, from about 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 0.75,or 0.8, mm to about 0.85, 0.9, 0.95, 1, 1.05, 1.1, 1.15, 1.2, 1.25, 1.3,1.35, 1.4, 1.5, 1.75, 2.0, 2.5, 3.0, 3.5, 4.0, 5.0, or 6.0 mm whereinthe first width 62 and the second width 74 are not the same. In variousembodiments, a first width 62 of a first region 60 is not the same as asecond width 74 of a second region 70. In various embodiments, a region,such as the second region 70, can also have a variable width within thatregion such as illustrated in FIG. 4.

In various embodiments, the first region 60 has a uniform width 62, asmeasured between the channel surface edges 52, and corresponds with acrest 80 which has a first depth 84 below the outer surface 36 of thetampon 10. In such embodiments, the second region 70 has a variablesecond width 74 within the second region 70 and the second width 70 isnot the same as the first width 62 of the first region 60. The secondregion 70 also corresponds with a trough 82 which has a second depth 86below the outer surface 36 of the tampon 10. In such embodiments, thenon-linear channel 50 undulates in each of the circumferential direction(X) and the radial depth direction (Z) as the non-linear channel 50extends in at least a portion of the longitudinal direction (Y) of thetampon 10.

In various embodiments, a tampon 10 can have at least 2, 3, 4, 5, 6, 7,8, 9, or 10 linear channels 40 and at least 2, 3, 4, 5, 6, 7, 8, 9, or10 non-linear channels 50. In various embodiments, a tampon 10 can havethe same number of linear channels 40 and non-linear channels 50. Invarious embodiments, a tampon 10 can have 4 linear channels 40 and 4non-linear channels 50. In various embodiments, a tampon 10 can have 6linear channels 40 and 6 non-linear channels 50. In various embodiments,a tampon 10 can have 8 linear channels 40 and 8 non-linear channels 50.In various embodiments, a tampon 10 can have 10 linear channels 40 and10 non-linear channels 50. In various embodiments, the number of linearchannels 40 can differ from the number of non-linear channels 50. Invarious embodiments, the linear channel(s) 40 and the non-linearchannel(s) 50 are present in an alternating pattern on the tampon 10. Alinear channel 40 can be positioned between two non-linear channels 50and a non-linear channel 50 can be positioned between two linearchannels 40. In various embodiments, the non-linear channels 50 arecongruent with each other such that the circumferential direction (X)undulation pattern of one non-linear channel 50 resembles thecircumferential direction (X) undulation pattern of another non-linearchannel 50. Two non-linear channels 50 can be considered congruent witheach other when their circumferential direction (X) undulation patternsresemble each other, however, such resemblance does not require thewidth between the sidewalls 54 of a first non-linear channel 50 to beidentical to the width between the sidewalls 54 of a second non-linearchannel 50. Congruency between non-linear channels 50 is determined byviewing the undulation pattern (i.e., the back-and-forth pattern) in thecircumferential direction (X).

In various embodiments, such as embodiments in which a non-linearchannel 50 does not extend the total length 24 of the tampon 10,additional topographical elements can be provided on the tampon 10wherein the additional topographical elements can be raised from theouter surface 36 and/or depressed into the outer surface 36 of thetampon 10. For example, the tampon 10 can have discrete indentations,discrete raised surfaces, and/or a circumferential raised ring in theportions of the tampon 10 wherein a non-linear channel 50 is notlocated.

In various embodiments, the tampon 30 can be placed into an applicator.In various embodiments, the tampon 30 may also include one or moreadditional features. For example, the tampon 30 may include a“protection” feature as exemplified by U.S. Pat. No. 6,840,927 to Hasse;U.S. 2004/0019317 to Takagi; U.S. Pat. No. 2,123,750 to Schulz, and thelike. In various embodiments, the tampon 30 can include an “anatomical”shape as exemplified by U.S. Pat. No. 5,370,633 to Villata, an“expansion” feature as exemplified by U.S. Pat. No. 7,387,622 to Pauley,an “acquisition” feature as exemplified by U.S. 2005/0256484 to Chase;an “insertion” feature as exemplified by U.S. Pat. No. 2,112,021 toHarris, a “placement” feature as exemplified by U.S. Pat. No. 3,037,506to Penska, or a “removal” feature as exemplified by U.S. Pat. No.6,142,984 to Brown.

Method and Apparatus:

A tampon blank 30 can undergo a compression step during themanufacturing process to form the pledget 12 of a tampon 10. Referringto FIG. 7, a schematic illustration of an exemplary method 100 forcompressing a tampon blank 30 in the manufacture of a pledget 12 for atampon 10 is illustrated. The method 100 includes a step 102 ofproviding a tampon blank 30 to a compression apparatus 110. The tamponblank 30 can be as described herein and has an initial diameter beforebeing inserted into the compression space 112 of the compressionapparatus 110. To compress the tampon blank 30 into the pledget 12 thecompression apparatus 110 has a set of compression jaws 120 and a set ofpenetration jaws 130. In various embodiments, the compression apparatus110 has at least 2, 3, 4, 5, 6, 7, 8, 9, or 10 compression jaws 120. Invarious embodiments, the compression jaws 120 are heated. In variousembodiments, the compression apparatus 110 has at least 2, 3, 4, 5, 6,7, 8, 9, or 10 penetration jaws 130. In various embodiments, thepenetration jaws 130 are heated.

Referring to FIGS. 8, 8A-8L, a compression jaw 120 can have acompression segment 122. The compression segment 122 is that portion ofthe compression jaw 120 which initiates compression of the tampon blank30 and which becomes surrounded by the absorbent material 14 of thetampon blank 30 during compression of the tampon blank 30. Thecompression segment 122 can have an opposing pair of sidewalls 124 whichjoin together to form a compression surface 126. Each of the opposingpair of sidewalls 124 extend in the longitudinal direction of thecompression space 112 of the compression apparatus so as to form achannel, such as linear channel 40, in the longitudinal direction (Y) ofa pledget 12 during the compression of the tampon blank 30. Thecompression segment 122 can have any shape as desired to produce thedesired shape and configuration of the linear channel 40. For example,in various embodiments, a linear channel 40 having a shape andconfiguration such as illustrated in FIG. 5A may be deemed suitable forthe pledget 12, and resultant tampon 10, and a compression segment 122can have the shape and configuration illustrated in FIG. 8A. Forexample, in various embodiments, a linear channel 40 having a shape andconfiguration such as illustrated in FIGS. 5B-5L may be deemed suitablefor the pledget 12, and resultant tampon 10, and a compression segment122 can have the shape and configuration such as illustrated in FIGS.8B-8L, respectively, (i.e., the compression segment 122 of FIG. 8B canproduce the channel of FIG. 5B, the compression segment 122 of FIG. 8Ccan produce the channel of FIG. 5C, the compression segment 122 of FIG.8D can produce the channel of FIG. 5D, the compression segment 122 ofFIG. 8E can produce the channel of FIG. 5E, the compression segment 122of FIG. 8F can produce the channel of FIG. 5F, the compression segment122 of FIG. 8G can produce the channel of FIG. 5G, the compressionsegment 122 of FIG. 8H can produce the channel of FIG. 5H, thecompression segment 122 of FIG. 8I can produce the channel of FIG. 5I,the compression segment 122 of FIG. 8J can produce the channel of FIG.5J, the compression segment 122 of FIG. 8K can produce the channel ofFIG. 5K, and the compression segment 122 of FIG. 8L can produce thechannel of FIG. 5L.

The plurality of compression segments 122 of the respective compressionjaws 120 guide the concentric positioning of the tampon blank 30 intothe compression space 112 of the compression apparatus 110. As thecompression segments 122 will guide the tampon blank 30 into thecompression space 112, the compression segments 122 should not inhibitthe movement of the tampon blank 30 into the compression space 112 ofthe compression apparatus 110 and the compression segments 122 can bedesigned to have a shape and configuration that can reduce frictionbetween the tampon blank 30 and the compression segments 122.

The plurality of compression segments 122 of the respective compressionjaws 120 are also used to guide the concentric positioning of thepledget 12 out of the compression apparatus 110 during the step ofejecting the pledget 12 from the compression apparatus 110. As thecompression segment 122 will guide the pledget 12 during ejection of thepledget 12 from the compression apparatus 110, the compression segment122 should not inhibit the movement of the pledget 12 from thecompression apparatus 110. As such, the compression segment 122 can bedesigned to have a shape and configuration that can reduce frictionbetween the pledget 12 and the compression segment 122.

During both insertion of a tampon blank 30 into the compression space112 and ejection of the pledget 12 from the compression space 112,therefore, the compression segments 122 of the compression jaws 120 arein contact with the tampon blank 30 or pledget 12, respectively, toprovide for concentric positioning relative to the longitudinal axis 114of the compression apparatus 110.

Referring to FIGS. 8, 8A-8L, to reduce the friction between the tamponblank 30 or pledget 12 and the compression segment 122, the compressionsegment 122 can be designed such that at least one of the sidewalls 124is oblique to a radial plane 128 directed outwards from the longitudinalaxis 114 of the compression space 112 of the compression apparatus 110.A radial plane 128 extends outward from the longitudinal axis 114 andcontains the longitudinal axis 114 of the compression space 112 of thecompression apparatus 110. A compression surface 126 has two compressionedges 118 that are parallel with the longitudinal axis 114 of thecompression apparatus 110. The two sidewalls 124 join together with thecompression surface 126 at a corresponding compression edge 118 to formthe compression segment 122 of compression jaw 120 to form acorrespondingly shaped linear channel 40.

The compression surface 126 can be any suitable width and contour toform the desired shaped inner surface 46 that defines the bottom of thelinear channel 40. Referring to FIGS. 5B, 5C, 5G, 5K, and 5L the linearchannel 40 contour of the inner surface 46 is formed by an arcuateshaped compression surface 126, and in FIGS. 5D, 5E, 5F, 5I, and 5J, thelinear channel 40 contour of the inner surface 46 is formed by a flatcompression surface 126.

The compression edges 118 of the compression surface 126 can either becoincident with one another to form a compression surface 126 such as inthe channel shape of FIGS. 5A and 5H, or the compression edges 118 canbe separated any suitable distance from one another to form a flat,arcuate, or contoured compression surface 126 to form a correspondingInner surface 46 of the linear channel 40.

Sidewalls 124 can be of any suitable contour including as flat orarcuate to form a correspondingly shaped linear channel 40 sidewall 44.Each compression segment 122 of the compression jaw 120 has a pair ofsidewalls 124 that have an engagement surface (i.e., that portion of thesidewall 124 which will contact the tampon blank 30), at least a portionof which defines a sidewall plane. A sidewall plane is tangent to therespective sidewall 124 surface and contains the correspondingcompression edge 118 of the compression surface 126 that contacts therespective sidewall 124. A lateral cross-section plane is orthogonal tothe longitudinal axis 114 of the compression space 112 and contains anacute angle 140 defined between the radial plan 128 and a first sidewallplane 182, and an acute angle 142 defined between the radial plane 128and a second sidewall plane 184, and a corresponding total angle 144 isdefined between the first sidewall plane 182 and the second sidewallplane 184.

At least one of the sidewalls 124 of the compression segment 122 isoblique to the radial plane 128 directed outward from the longitudinalaxis of the compression space 122. Referring to FIGS. 8 and 8A-8L, thecompression segment 122 has a first sidewall 124 having an acute angle140 from the radial plane 128 from about 0, 5, 10, 15, 35, or 40 degreesto about 45, 50, 55, 60, 65, 70, 80, or 89 degrees and the secondsidewall 124 has an acute angle 142 from the radial plane from about 0,5, 10, 15, 35, or 40 degrees to about 45, 50, 55, 60, 65, 70, 80, or 89degrees. A total angle 144 between the two opposing sidewall planes, 182and 184, of sidewalls 124 can be from about 10, 20, 30, 35 or 40 toabout 45, 60, 70, 80, 90, 120, 150, or 178 degrees.

To form a non-linear channel, such as non-linear channel 50, into thetampon blank 30, the compression apparatus can have penetration jaws130. A penetration jaw 130 can have a base surface 134 with multiplepenetration segments 132 extending outwardly from the base surface 134.The penetration segments 132 can be of any shape, size, or configurationas deemed suitable. In various embodiments, the penetration jaw 130 canhave at least 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 30, or 35penetration segments 132 extending from the base surface 134. Referringto FIGS. 9A-9D, an exemplary embodiment of a penetration jaw 130 isillustrated. FIG. 9A illustrates a perspective view of a penetration jaw130, FIG. 9B is a bottom view of the penetration jaw 130 of FIG. 9A,FIG. 9C is a side view of the penetration jaw 130 of FIG. 9A so thepenetration surfaces 172 of the penetration segments 132 are visible tothe viewer, and FIG. 9D is a close-up of a portion of the penetrationjaw 130 of FIG. 9C. In various embodiments, the penetration jaw 130 canhave a longitudinal direction (Y) such that it extends in thelongitudinal direction of the compression space 112 of the compressionapparatus 110. The penetration jaw 130 further has a lateral direction(X). The base surface 134 can have a width dimension 150, as measured inthe lateral direction (X), from about 1.6 or 1.7 mm to about 1.8, 1.9,2.0, 2.2, 2.4, 2.6, 2.8, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, or 6.0 mm. Thepenetration segments 132 can extend from the base surface 134 of thepenetration jaw 130 any distance 158 as deemed suitable such that thepenetration segments can penetrate into the tampon blank 30 duringcompression of the tampon blank 30. In various embodiments, thepenetration segments 132 can extend a distance 158 from the basesurface, as measured from the base surface 134 to the outermost point ofthe penetration segment 132, of from about 0.6, 0.8, 1.0, 1.2, 1.4,1.45, 1.5, 1.55, 1.6, or 1.65 mm to about 1.7, 1.75, 1.8, 1.85, 1.9,1.95, 2.05, 2.25, 2.45, 2.55, 2.65, or 2.75 mm.

As the penetration jaw 130 can have multiple penetration segments 132extending outwardly from the base surface 134, the penetration segments132 can be in a spaced apart relationship from each other. In variousembodiments, the distance 166 from one penetration segment 132 to thenext successive penetration segment can be from about 0.2, 0.4, 0.6,0.8, 1, 1.2, 1.4, 1.6, 1.8, 2, 2.6, 3, 3.6, or 4 mm to about 4.6, 5,5.6, 6, 6.6, 7, 7.6, or 8 mm. In various embodiments, the penetrationsegments 132 can be evenly spaced apart from each other, such asillustrated in FIGS. 9A-9D. In various embodiments, the penetrationsegments 132 can vary in their spacing, such as illustrated in FIGS. 10and 10A. FIG. 10 provides a side view of an exemplary embodiment of apenetration jaw 130 with multiple penetration segments 132 extendingoutwardly from the base surface 134 and FIG. 10A provides a bottom viewof the penetration jaw 130 of FIG. 10. As illustrated in FIGS. 10 and10A, the penetration segments 132 are in the shape of concentric conesand are spaced apart from each other in a variable distance.

A penetration segment 132 can have a length dimension 160 and a widestwidth dimension 162. The length dimension 160 can be measured in thelongitudinal direction (Y) of the penetration jaw 130 and the widestwidth dimension 162 can be measured in the lateral direction (X) of thepenetration jaw 130. In various embodiments, the length dimension 160 ofthe penetration segment 132 can be from about 1.5, 1.6, 1.7, 1.8, 1.9,2, 22, 2.4, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, or 4 mm to about 4.2, 4.4,4.6, 4.8, 5, 5.2, 5.4, 5.6, 5.8, 6, 6.2, 6.4, 6.6, 6.8, 7, 7.2, 7.4,7.6, 7.8 or 8 mm. For example, the length dimension 160 of thepenetration segment 132 illustrated in FIG. 9D can be measured betweenthe opposing tips 138 of the penetration segment 132. In variousembodiments, the penetration segment 132 can have a widest widthdimension 162. Such a widest width dimension 162 can be measured at thewidest width of the penetration segment 132 in the lateral direction (X)of the penetration jaw 130. In various embodiments, the widest widthdimension 162 of the penetration segment can be from about 1, 1.2, or1.4 mm to about 1.6, 1.7, 1.8, 2.0, 2.2, 2.4, 2.6, 2.8, 3.0, 3.5, 4.0,4.5, 5.0, 5.5, or 6.0 mm.

The penetration segment 132 has a pair of opposing sidewalls 170 whichextend away from the base surface 134 and join together to form apenetration surface 172. In various embodiments, the penetration segment132 can be provided in a variety of shapes and configurations. Invarious embodiments, the penetration segment 132 can be provided inshapes such as an oval, cone, triangle, diamond, circle, or tilde. Invarious embodiments, a penetration segment 132 can have a variable widthdimension 174 between the opposing pair of sidewalls 170 in the lateraldirection (X) as the penetration segment 132 extends in the longitudinaldirection (Y) of the penetration jaw 130. The variable width dimension174 of the penetration segment 132 is, therefore, a measurement betweenthe sidewalls 170 of the penetration segment 132 while the widest widthdimension 162 is a measurement of the overall width of the penetrationsegment 132 in the lateral direction (X) of the penetration jaw 130. Forexample, as illustrated in FIGS. 9A-9D, the penetration segment 132 isin the shape of a tilde. As illustrated, the widest width dimension 162of the penetration segment 132 is substantially similar to the fullwidth dimension 150 of the base surface 134, however, the actualpenetration segment 132, as a tilde, has a variable width dimension 174between the opposing sidewalls 170 in the lateral direction (X) as thetilde extends in the longitudinal direction (Y) of the penetration jaw130. In various embodiments, the variable width dimension 174 of thepenetration segment 132 can be from about 0.3, 0.35, 0.4, 0.45, 0.5,0.55 or 0.6 mm to about 0.65, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, 1, 1.05,1.1, 1.15, 1.2, 1.25, 1.3, 1.35, or 1.4 mm.

In various embodiments, the penetration segments 132 can be provided ina pattern of penetration segments 132. In various embodiments, thepattern can have a single style and configuration of penetration segment132 such as illustrated in FIGS. 9A-9D. In various embodiments, thepattern can have at least two styles of penetration segments 132, suchas penetration segments 132A and 132B illustrated in FIGS. 11, 11A, and12. The pattern of penetration segments can be provided in a repeatingpattern wherein a distance 164 from one pattern to the next pattern canbe from about 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 7, 7.5, or 8 mm toabout 8.5, 9, 9.5, or 10 mm. As illustrated in FIGS. 11 and 11A, thepattern can be a repeating pattern of penetration segments, 132A and132B, in the style of a tilde and concentric cone, respectively. Asillustrated in FIG. 12, the pattern can be a repeating pattern ofpenetration segments, 132A and 132B, of a tilde and circular cylinder.In various embodiments, the penetration segments 132 on a penetrationjaw can be of at least two different styles wherein each style isgrouped together to provide for a tampon 10 having a non-linear channel50 wherein different portions of the non-linear channel 50 are ofdifferent patterns. Referring to FIG. 13, a tampon 10 can have anon-linear channel 50 in which a first portion of a non-linear channel50 is linked circles and a second portion of the non-linear channel 50is a tilde pattern.

In various embodiments, the penetration segments 132 can extend in atleast a portion of the longitudinal direction (Y) of the penetration jaw130. In various embodiments, the penetration segments 132 can extend thetotal length of the penetration jaw 130 in the longitudinal direction(Y). In various embodiments, the penetration segments 132 can extend aportion of the total length of the penetration jaw 130 in thelongitudinal direction (Y). For example, the penetration segments 132can be positioned on the length of the penetration jaw 130 in thelongitudinal direction (Y) such that the resulting tampon 10 can have anon-linear channel 50 which can extend from the insertion end 20 toapproximately the middle of the tampon length 24 of the tampon 10. Invarious embodiments, the penetration segments 132 can be positioned onthe length of the penetration jaw 130 in the longitudinal direction (Y)such that the resulting tampon 10 can have a non-linear channel 50 whichextends only a portion of the tampon length 24 of the tampon 10 such asa non-linear channel 50 which extends from the insertion end 20 to themiddle of the tampon length 24 of the tampon 10, from the withdrawal end22 to the middle of the tampon length 24 of the tampon 10, or can bepresent in the middle third of the tampon 10 without extending to eitherof the insertion end 20 or withdrawal end 22. In various embodiments,the penetration segments 132 can be positioned on the length of thepenetration jaw 130 in the longitudinal direction (Y) such that theresultant tampon 10 can have multiple non-linear channels 50 present ina common region of the tampon 10 such as, for example, a tampon 10 canhave a first non-linear channel 50 in a spaced apart relationship in thelongitudinal direction (Y) from a second non-linear channel 50. Forexample, a tampon 10 can have a first non-linear channel 50 present atthe insertion end 20 and extending in the longitudinal direction (Y)towards the middle of the tampon length 24 of the tampon 10 and a secondnon-linear channel 50 present at the withdrawal end 22 of the tampon andextending towards the middle of the tampon length 24 of the tampon 10wherein the first non-linear channel 50 and the second non-linearchannel 50 are present in the same longitudinal plane of the tampon 10and separated from each other by a distance in the longitudinaldirection (Y).

An example of an embodiment of a penetration jaw 130 is illustrated inFIGS. 9A-9D. In the example illustrated in FIGS. 9A-9D, the penetrationjaw 130 has a base surface 134 and eight penetration segments 132 in theshape of a tilde extending outwardly from the base surface 134 of thepenetration jaw. Each penetration segment 132 extends outwardly from thebase surface 134 at a distance 158 of about 1.85 mm. The base surface134 has a width dimension 150 of about 2.5 mm and the penetrationsegments 132 have a widest width dimension 162 of about 1.8 mm. Eachpenetration segment 132 is evenly spaced from each successivepenetration segment 132 at a distance 166 from about 0.2 mm to about 1.7mm. The length dimension 160 of each penetration segment 132 can be fromabout 6.2 mm to about 7.8 mm. The penetration segments 132, in the shapeof a tilde, can have a variable width 174 between the opposing sidewalls170 which can be from about 0.3 mm to about 1.4 mm. The penetrationsegments 132 are provided on the penetration jaw 130 in a repeatingpattern of the single style of penetration segments 132, the tilde.

An example of an additional embodiment of a penetration jaw 130 isillustrated in FIGS. 11 and 11A. In the example illustrated in FIGS. 11and 11A, the penetration jaw 130 has a base surface 134 and thirteenpenetration segments 132 extending outwardly from the base surface 134.Each penetration segment, 132A and 132B, extends outwardly from the basesurface 134 at a distance of about 1.85 mm. The base surface 134 has awidth dimension of about 2.5 mm and the penetration segment 132 have awidest width dimension 162 of about 1.8 mm. Each penetration segment,132A or 132B, is evenly spaced from each successive penetration segment,132A or 132B, at a distance of about 0.4 mm. The length dimension 160 ofeach penetration segment 132A is about 7 mm and the length dimension 160of each penetration segment 132B is about 2 mm. The penetration segment132A, in the shape of a tilde, can have a variable width between theopposing sidewalls 170 which can be from about 0.3 mm to about 1.4 mm.The penetration segments 132 are provided on the penetration jaw 130 ina repeating pattern of two styles and shapes of penetrating segmentswherein penetration segment 132A is in the shape of a tilde andpenetration segment 132B is in the shape of a concentric circular ring.

In various embodiments, the compression jaws 120 and the penetrationjaws 130 can be provided in a compression apparatus 110 wherein thecompression apparatus 110 will open and close the compression jaws 120and penetration jaws 130 in a radial direction along an arcuate path,such as a compression apparatus 110 illustrated in FIGS. 14-17. FIG. 14is a schematic illustration of a compression apparatus wherein thecompression jaws 120 and the penetration jaws 130 move in an arcuatepath towards the longitudinal axis 114 of the compression space 112 ofthe compression apparatus 110 and wherein the compression jaws 120 andthe penetration jaws 130 are in an open configuration. FIG. 15 is aschematic illustration of the compression apparatus 110 of FIG. 14 withthe compression jaws 120 in a closed configuration and compressing atampon blank 30 to form a tampon pledget 12. FIG. 16 is a schematicillustration of the compression apparatus 110 of FIG. 14 with thecompression jaws 120 and penetration jaws 130 in a closed configurationand not compressing the tampon pledget 12. FIG. 17 is a schematicillustration of the compression apparatus 110 of FIG. 14 with thepenetration jaws 130 in an open configuration and completely withdrawnfrom the tampon pledget 12 and the compression jaws 120 in a closedconfiguration.

In various embodiments, the compression jaws 120 and the penetrationjaws 130 can be provided in a compression apparatus 110 wherein thecompression apparatus 100 will open and close the compression jaws 120and penetration jaws 130 in a radial direction along a linear path, suchas compression apparatus 110 illustrated in FIG. 18. FIG. 18 is aschematic illustration of a compression apparatus 110 wherein thecompression jaws 120 and penetration jaws 130 move in a linear pathtowards the longitudinal axis 114 of the compression space 112 of thecompression apparatus 110 and wherein the compression jaws 120 and thepenetration jaws 130 are in an open configuration.

Prior to the insertion of a tampon blank 30 into the compression space112 of the compression apparatus 110, the compression jaws 120 and thepenetration jaws 130 are in a fully open position, such as illustratedin FIG. 14 and FIG. 18, to allow for insertion of the tampon blank 30into the compression space 112. The tampon blank 30 is inserted into thecompression space 112 of the compression apparatus 110 and within thecompression apparatus 110 the method 100 includes a step 104 ofcompressing the tampon blank 30 by utilizing the compression jaws 120and the penetration jaws 130. The compression of the tampon blank 30 isaccomplished by moving each of the compression jaws 120 and penetrationjaws 130 in a direction towards a longitudinal axis 114 of thecompression space 112 of the compression apparatus 110. As each of thecompression jaws 120 and penetration jaws 130 are moved in a directiontowards the longitudinal axis 114 of the compression space 112 themovement of each of the compression jaws 120 and penetration jaws 130can be in either an arcuate path, such as illustrated in FIGS. 14-17, ora linear path, such as illustrated in FIG. 18.

The compression jaws 120 and the penetration jaws 130 are in an openposition when the tampon blank 30 is inserted into the compression space112 of the compression apparatus 110. The compression jaws 120, while inthe open position, will make contact with the tampon blank 30 during theinsertion of the tampon blank 30 to provide for concentric positioningof the tampon blank 30 into the compression space 112 of the compressionapparatus 110. The penetration jaws 130, however, will not contact thetampon blank 30 during the insertion of the tampon blank 30 into thecompression space 112 of the compression apparatus 110. The sidewalls124 of the compression jaws 120 guide the tampon blank 30 such that thelongitudinal axis of the tampon blank 30 is aligned with thelongitudinal axis of the compression apparatus 110 during insertion ofthe tampon blank 30 into the compression apparatus 110 while thecompression jaws 120 are in the open position. After the tampon blank 30is inserted into the compression apparatus 110, the compression jaws 120and the penetration jaws 130 move to a closed position during thecompression step 104. In various embodiments, the compression jaws 120operate independently from the penetration jaws 130. In variousembodiments, the compression step 104 can occur via the sequentialoperation of the compression jaws 120 and the penetration jaws 130. Invarious embodiments, the compression step 104 can occur via asimultaneous operation of the compression jaws 120 and penetration jaws130. In various embodiments, the compression jaws 120 and thepenetration jaws 130 operate with a least a portion of the relativemotion being asynchronous with each other. The concentric alignment ofthe tampon blank 30 by the compression jaws 120 during the insertion ofthe tampon blank 30 ensures that the tampon blank 30 is uniformlycompressed from the initial diameter to form a compressed pledget 12having a compressed diameter.

The method 100 also includes a step 106 of ejecting the pledget 12 fromthe compression apparatus 110 by retracting the penetration jaws 130fully from the pledget 12 to the open configuration and maintaining thecompression jaws 120 in a closed position such as illustrated in FIG.17. Attempting to eject a pledget 12 from the compression apparatus 110with the penetration jaws 130 either partially or fully in a closedposition and with the penetration segments 132 at least partiallyengaged with the absorbent material 14 of the pledget 12 will result indamage to the pledget 12 as the absorbent material 14 of the pledget 12can be snagged or scuffed by the penetration segments 132 located on thepenetration jaws 130. The compression jaws 120 in the closed positionmaintains the pledget 12 in a concentric alignment with the longitudinalaxis of the compression apparatus 110, maintains the pledget 12 in afully compressed configuration, and maintains the pledget 12 within thelongitudinal center of the compression space 112 of the compressionapparatus 110 during the ejection of the compressed pledget 12 from thecompression space 112. The compression jaws 120 thus concentricallyguide the pledget 12 out of the compression space 112 of the compressionapparatus 110 by remaining in the fully closed configuration. Asdescribed herein, having at least one sidewall 124 which is oblique to aradial plane directed outward from the longitudinal axis 114 of thecompression space 112 can reduce any potential friction between thecompressed pledget 12 and the compression segment 122 of the compressionjaw 120. Following the ejection of the pledget 12 from the compressionspace 112 of the compression apparatus 110, the compression jaws 120 areretracted from the closed position to the open position. Throughout theoperation of the method 100, the compression jaws 120 can dwell in aposition that is either a full open position to receive a tampon blank30 or a full closed position to eject a compressed tampon pledget 12.Neither the compression jaws 120 nor the penetration jaws 130 stop theirmovement at an intermediate position between the full open position orthe full closed position to either receive a tampon blank 30 or eject acompressed tampon pledget 12 from the compression space 112 of thecompression apparatus 110.

A pledget 12, and a result tampon 10, can be compressed according to themethod 100 described herein. The pledget 12, and the resultant tampon10, can have a linear channel 40 and a non-linear channel 50. The linearchannel 40 is the result of the compression of the tampon blank 30 bythe compression jaws 120. The non-linear channel 50 is the result of thecompression of the tampon blank 30 by the penetration jaws 130.Penetration jaws 130 which are designed as described herein, apenetration jaw 130 with multiple discrete penetration segments 132, canproduce a non-linear channel 50 that is a continuous channel extendingin the longitudinal direction (Y) of the tampon 10. The non-linearchannel 50 can have undulations in the radial depth direction (Z) and,in various embodiments, can also have undulations in the circumferentialdirection (X) of the tampon 10. As described herein, the undulations inthe radial depth direction (Z) is a pattern of crests 80 and troughs 82.The troughs 82 are formed by the penetration into the tampon blank 30 bythe penetration segments 132 of the penetration jaws 130. The crests 80are formed as a result of the absorbent material 14 and cover materiallocated between the segments of absorbent material 14 which is beingcompressed by the penetration segments 132 being pulled downward such asinto a fold. The absorbent material 14 and the cover material can folddownwards even though not actually under compression due to a variety ofproperties. Such properties include the material properties of the covermaterial such as, percent stretch to failure, thickness, and tensilestrength, as well as the density and moisture of the absorbent material14. An additional property which influences the ability for theabsorbent material 14 and cover material to fold include the distancebetween each penetration segment 132 whereas a distance greater thanabout 8 mm between the penetration segments 132 may not result in acrest 80 in the pledget 12. The shape and orientation of the penetrationsegments 132 has also been found to influence whether a fold downward ofthe absorbent material 14 occurs. For example, a square or rectangularshaped penetration segment 132 may not produce a crest 80 in the pledget12, however, penetration segments 132 which have a variable width andwherein a taper in the variable width of one penetration segment 132 isnearby to a taper in the variable width of the next successivepenetration segment has been found to result in a crest 80 in thepledget 12. Other factors which may influence the ability for thepenetration jaw 130 to produce a crest 80 in a pledget 12 include theorientation of the penetration segments 132 to the longitudinal axis 114of the compression space 112 of the compression apparatus 110, theextent of the distance of extension of the penetration segments 132 fromthe base surface 134 of the penetration jaw 130, and the amount ofcompression pressure utilized to form the non-linear channel 50 in thecompression of the tampon blank 30 to a pledget 12.

In the interests of brevity and conciseness, any ranges of values setforth in this disclosure contemplate all values within the range and areto be construed as support for claims reciting any sub-ranges havingendpoints which are whole number values within the specified range inquestion. By way of hypothetical example, a disclosure of a range offrom 1 to 5 shall be considered to support claims to any of thefollowing ranges: 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2 to 5; 2 to 4; 2 to3; 3 to 5; 3 to 4; and 4 to 5.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by references, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

When introducing elements of the present disclosure or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. Many modifications and variations of the present disclosurecan be made without departing from the spirit and scope thereof.Therefore, the exemplary embodiments described above should not be usedto limit the scope of the invention.

What is claimed is:
 1. A method for compressing a tampon blank into apledget, the method comprising the steps of: a) providing a compressionapparatus for compressing the tampon blank, the compression apparatuscomprising: i) a compression space and a longitudinal axis; ii) aplurality of compression jaws wherein each compression jaw comprises acompression segment which has a first sidewall and an opposing secondsidewall wherein the first sidewall and the second sidewall jointogether to form a longitudinal direction compression surface wherein atleast one of the first sidewall and the second sidewall is oblique to aradial plane directed outward from the longitudinal axis; iii) aplurality of penetration jaws wherein each penetration jaw comprises: 1)a base surface comprising a longitudinal direction and at least twopenetrating segments extending from the base surface wherein a first ofthe at least two penetrating segments is spaced apart from a second ofthe at least two penetrating segments and wherein each of thepenetrating segments comprises a first sidewall and an opposing secondsidewall wherein the first sidewall and the second sidewall jointogether to form a compression surface; b) inserting the tampon blankinto the compression space of the compression apparatus wherein thetampon blank comprises a longitudinal direction, a longitudinal axis, acircumferential direction, and a radial depth direction; c) moving thecompression jaws in a direction towards the longitudinal axis of thecompression apparatus wherein the compression jaws move from an openposition to a closed position to form a pledget; d) moving thepenetration jaws in a direction towards the longitudinal axis of thecompression apparatus wherein the penetration jaws move from an openposition to a closed position to form a non-linear channel in thepledget; e) retracting the penetration jaws from the pledget in adirection away from the longitudinal axis of the compression apparatuswherein the penetration jaws move from the closed position to the openposition; f) ejecting the pledget from the compression apparatus; and g)retracting the compression jaws in a direction away from thelongitudinal axis of the compression space wherein the compression jawsmove from the closed position to the open position.
 2. The method ofclaim 1 wherein the compression apparatus comprises from 2 to 10compression jaws.
 3. The method of claim 1 wherein the compressionapparatus comprises from 2 to 10 penetration jaws.
 4. The method ofclaim 1 wherein the movement of the compression jaws and the penetrationjaws is in an arcuate path in a radial direction toward the longitudinalaxis of the compression space.
 5. The method of claim 1 wherein themovement of the compression jaws and the penetration jaws is in a linearpath in a radial direction toward the longitudinal axis of thecompression space.
 6. The method of claim 1 wherein each penetration jawcomprises from 2 to 35 penetration segments extending from the basesurface.
 7. The method of claim 1 wherein the penetration segments havea variable width between the two opposing sidewalls.
 8. The method ofclaim 1 wherein the compression jaws are heated.
 9. The method of claim1 wherein the penetration jaws are heated.
 10. The method of claim 1wherein the penetration jaws operate independently from the compressionjaws.
 11. The method of claim 1 wherein each penetration jaw operatessynchronously with each other penetration jaw.
 12. The method of claim 1wherein each compression jaw operates synchronously with each othercompression jaw.
 13. The method of claim 1 wherein a longitudinal axisof the pledget is concentrically aligned with the longitudinal axis ofthe compression apparatus when the pledget is ejected from thecompression apparatus.
 14. The method of claim 1 wherein the penetrationjaws are disengaged from the pledget during ejection of the pledget. 15.The method of claim 1 wherein the compression jaw forms a linear channelin the tampon blank.
 16. The method of claim 1 wherein the penetrationjaws are in an open position during insertion of the tampon blank intothe compression apparatus.
 17. The method of claim 1 wherein thelongitudinal axis of the tampon blank is concentrically aligned with thelongitudinal axis of the compression apparatus during insertion of thetampon blank into the compression apparatus.
 18. The method of claim 1wherein each penetration jaw forms a single non-linear channel in thepledget.
 19. The method of claim 1 wherein each penetration jaw forms aplurality of non-linear channels in the pledget.
 20. The method of claim1 wherein ejecting the pledget from the compression apparatus occurswhile the plurality of compression jaws are in the closed position. 21.The method of claim 1 wherein the compression jaws and the penetrationjaws operate with at least a portion of the relative motion beingasynchronous with each other.